Method and system for exposure of a phase shift mask

ABSTRACT

The present disclosure provides a method of making a mask. The method includes providing a substrate having a first attenuating layer on the substrate and a first imaging layer on the first attenuating layer; performing a first exposure to the first imaging layer using a first radiation energy in writing mode; performing a first etching to the first attenuating layer; performing a second etching to the substrate; forming a second imaging layer on the first attenuating layer and the substrate; performing a second exposure to the second imaging layer using a light energy and another mask; and performing a third etching to the first attenuating layer after the second exposure.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation application of U.S. patentapplication Ser. No. 11/695,186, filed Apr. 2, 2007 which is herebyincorporated by reference in its entirety.

BACKGROUND

The present disclosure relates in general to semiconductor manufacturingtechnology, and more particularly, to a process of making and usingphotomasks or masks. The present disclosure also relates to a method andsystem for exposing a phase-shift mask in the semiconductormanufacturing process.

In semiconductor manufacturing technology, phase-shift masks (PSM) havebeen used to overcome problems associated with light diffraction and toenhance the lithography exposure resolution. Currently, in the processof making a PSM, a user-supplied pattern is produced on the PSM by anelectron beam (e-beam) or laser writing lithography process. Typically,the time it takes to make a single mask with one of these types ofsystems is about 2 hours or longer. In addition, the e-beam or laserwriting lithography system itself is very costly. Therefore, a needexists for a method and system that reduces the time and cost it takesto produce a PSM.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isemphasized that, in accordance with the standard practice in theindustry, various features are not drawn to scale. In fact, thedimensions of the various features may be arbitrarily increased orreduced for clarity of discussion.

FIG. 1 is a flowchart of one embodiment of a method for making a phaseshift mask.

FIGS. 2 through 7 are sectional views of one embodiment of a phase shiftmask at various fabrication stages fabricated using the method of FIG.1.

FIG. 8 is a flowchart of another embodiment of a method for making aphase shift mask.

FIGS. 9 through 14 are sectional views of one embodiment of a phaseshift mask at various fabrication stages fabricated using the method ofFIG. 8.

FIG. 15 is a schematic view of one embodiment of a lithography systemcapable of an exposure process in writing mode.

FIG. 16 is a schematic view of one embodiment of a lithography systemcapable of an exposure process in scanning mode.

FIG. 17 is a top view of a phase shift mask fabricated using the methodof FIG. 1.

DETAILED DESCRIPTION

It is to be understood that the following disclosure provides manydifferent embodiments, or examples, for implementing different featuresof various embodiments. Specific examples of components and arrangementsare described below to simplify the present disclosure. These are, ofcourse, merely examples and are not intended to be limiting. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

FIG. 1 is a flowchart of a method 100 for making a phase shift maskaccording to one embodiment of the present invention. FIGS. 2 through 7are sectional views of an exemplary phase shift mask 200 at variousfabrication stages fabricated using the method 100. With reference toFIGS. 1 through 7, the method 100 and the phase shift mask 200fabricated thereby are collectively described below.

The method 100 begins at step 102 by providing a mask (also referred toas a photomask or reticle) 200 having a substrate 210, a firstattenuating layer 220, a second attenuating layer 230, and a firstimaging layer 240, as illustrated in FIG. 2. The mask 200 describedabove is also referred to as a mask blank, at this stage, to bepatterned to form a phase shift mask for use in semiconductor waferfabrication. The substrate 210 is transparent and includes fused silica(SiO₂) relatively free of defects. The substrate 210 may alternativelyinclude calcium fluoride, or other suitable material.

The first attenuating layer 220 is disposed on the substrate 210 and isdesigned to provide a phase shift to a radiation beam employed in alithography process for semiconductor wafer fabrication. The firstattenuating layer 220 may have a thickness such that the radiation beamdirected toward and through the first attenuating layer 120 has a phaseshift relative to the radiation beam directed through air. The radiationbeam may be ultraviolet and/or can be extended to include otherradiation beams such as ion beam, x-ray, extreme ultraviolet (EUV), deepultraviolet (DUV), and other proper radiation energy. In one embodiment,the first attenuating layer 220 provides a phase shift of about 180degrees. More specifically, the first attenuating layer 220 may have athickness about λ/[2(n−1)], wherein λ is the wavelength of the radiationbeam projected on the mask 100 during a photolithography process forwafer fabrication, and n is refractive index of the first attenuatinglayer 220 relative to the radiation beam. In another embodiment, thefirst attenuating layer 220 may provide a phase shift ranging betweenabout 120 degrees and 240 degrees. Specifically, the first attenuatinglayer 220 may have a thickness ranging between λ/[3×(n−1)] and2λ/[3×(n−1)] to realize a desired phase shift in the above range. Thefirst attenuating layer 220 may have a transmission less than one (or100%) and more than zero. In one example, the first attenuating layer220 may have a transmission higher than about 5%. The first attenuatinglayer 220 includes MoSi. Alternatively, the first attenuating layer 220may include a material selected from the group consisting of metalsilicide such as MoSi or ToSi₂, metal nitride, iron oxide, inorganicmaterial, other materials such as Mo, Nb₂O₅, Ti, Ta, CrN, MoO₃, MoN,Cr₂O₃, TiN, ZrN, TiO₂, TaN, Ta₂O₅, SiO₂, NbN, Si₃N₄, ZrN, Al₂O₃N, orcombinations thereof. The method of forming the first attenuating layer220 may include chemical vapor deposition (CVD), physical vapordeposition (PVD), atomic layer deposition (ALD), plating, and/or othersuitable processes.

The second attenuating layer 230 is disposed on the first attenuatinglayer 220. The second attenuating layer 230 is designed as an absorptionlayer and is opaque to the radiation beam used for lithographyprocessing in semiconductor wafer fabrication. The second attenuatinglayer 230 has a transmission less than that of the first attenuatinglayer 220. In one embodiment, the second attenuating layer 230 has asubstantially zero transmission. In another embodiment, the secondattenuating layer 230 has a transmission less than about 30%. The secondattenuating layer 130 may utilize a material different from that of thefirst attenuating layer 120. In one embodiment, the second attenuatinglayer 230 includes chromium. Alternatively, the second attenuating layer230 may include a material selected from the group consisting of Cr,CrN, Mo, Nb₂O₅, Ti, Ta, CrN, MoO₃, MoN, Cr₂O₃, TiN, ZrN, TiO₂, TaN,Ta₂O₅, SiO₂, NbN, Si₃N₄, ZrN, Al₂O₃N, or a combination thereof. Themethod of forming the second attenuating layer 230 may include CVD, PVD,plating, and/or other suitable processes.

The first imaging layer 240 is formed on the second attenuating layer230. The imaging layer 240 is sensitive to a radiation energy employedin the first exposure described below. For example, the first imaginglayer is a resist that is sensitive to an e-beam. The first imaginglayer 240 can be formed by a spin-on coating method. The first imaginglayer 240 may be further soft baked.

The method 100 proceeds to step 104 to perform a first exposure appliedto the first resist layer 240. The first exposure to the resist layer240 utilizes a radiation beam such as electronic beam (e-beam) to exposethe resist layer 240 in a writing mode. The first exposure may utilizean e-beam writer 500 as illustrate in FIG. 15. In the e-beam writer 500,a mask 510, such as the phase shift mask 200 of FIG. 2 through FIG. 7,is supported by a substrate stage 520. An electron source 530 produceselectrons that are focused in the shape of a beam 540 toward the mask510. The electron beam 540 shines on the mask 510 in a writing mode toexpose a desired pattern across an e-beam resist on the surface of themask 510. Alternatively, a laser writer may be utilized for the firstexposure by a laser beam in writing mode.

After the first exposure, other lithography processes may be applied tothe imaging layer 240 to form various openings such as openings 240 aand 240 b, designed according to a predefined structure to be imagedonto a semiconductor wafer or other integrated circuit substrate. Thesecond attenuating layer 230 is exposed within the openings 240 a and240 b of the imaging layer 240, as illustrated in FIG. 3. The otherlithography processes applied to the imaging layer 240 may includepost-exposure baking, developing, and hard baking.

Referring to FIGS. 1 and 4, the method 100 proceeds to step 106 byetching the first and second attenuating layers through the openings 240a and 240 b of the patterned imaging layer 240 to form various openings230 a and 230 b through the first and second attenuating layers 220 and230. The transparent substrate 210 is therefore exposed within theopenings 230 a and 230 b. The etchant for etching the first and secondattenuating layers 220 and 230 may be chosen or designed to have ahigher etching selectivity over the transparent substrate 210. Theetchant may include halogens species such as fluorine, chlorine andbromine. The first and second attenuating layers 220 and 230 may beetched separately in two etching steps each using a certain etchant. Thepatterned imaging layer 240 is removed after the etching process appliedto the two attenuating layers 220 and 230.

Referring to FIGS. 1 and 5, the method 100 proceeds to step 108 byforming a second imaging layer 250 on the mask 200. The second imaginglayer 250, such as a photoresist (resist) layer, is sensitive to theradiation energy employed in the second exposure described below. Theresist layer 250 is formed on the second attenuating layer 230 and alsoon the transparent substrate 210 within the openings 230 a and 230 b.The exemplary resist material for the second imaging layer 250 mayinclude chemical amplification resist (CAR). The resist layer 250 may beformed by a spin-on coating process and may be thereafter soft baked.

Referring to FIGS. 1 and 6, the method 100 proceeds to step 110 byperforming a second exposure to the second imaging layer 250 utilizing aradiation energy in scanning mode. The second exposure utilizes a lightsuch as ultra-violet (UV) as the radiation energy and another mask withpredefined pattern for the second exposure. The second exposure appliedto the resist layer 250 utilizes a lithography exposure tool 600 to scana predefined pattern, as illustrated in FIG. 16. The exposure system 600includes an illumination module (e.g., a condenser) 610 having a singlelens, or multiple lenses and other lens components, designed to aid indirecting radiation beams from a radiation source (not shown) onto areticle 620. The radiation source provides radiation beams with awavelength in a range of ultra-violet (UV) or deep ultra-violet (DUV).The exposure system 600 further includes an imaging lens module 640. Theimaging lens module 640 may have a single lens or a plurality of lenselements configured to project the radiation beam onto a mask 660 to befabricated such as the phase shift mask 200 of FIG. 5. Reticle 620includes a pattern 630. When the radiation beam passes through theimaging lens module 640 by scanning, an image 650 is exposed onto themask 660. In one example, the imaging lens module 640 includes a 1×projection lens module or other scales of reduction lens. With exposuresystem 600, a single PSM for the second exposure may take about five toten minutes instead of 2.5 hours. In addition, the exposure system 600may be used for certain resolution patterns, such as 3 um resolutionpatterns. Furthermore, the exposure system 600 may have good alignmentaccuracy, such as 0.5 um alignment accuracy. Exposure system 600 is alsoless costly than a laser beam writer. By employing the exposure system600 to perform the second exposure, the overall throughput, cycle time,and cost of producing a phase shift mask is improved. It is noted thatin addition to PSM, aspects of the present disclosure may be implementedto produce other types of masks without departing the spirit and scopeof the present disclosure. The exposure system 600 may further step tovarious subfields of the mask 200 and scan each of the subfields. Theexposure system 600 may be a stepper, or a scanner in variousembodiments.

After the second exposure, other lithography processes may be applied tothe resist layer 250 for patterning thereof to form various openingssuch as an openings 250 a, designed according to a predefined structureto be imaged onto a semiconductor wafer or other integrated circuitsubstrate. The second attenuating layer 230 and the transparentsubstrate 210 are exposed within the openings 250 a of the resist layer250. The other lithography processes applied to the resist layer 250 mayinclude post-exposure baking, developing resist, and hard baking.

Referring to FIGS. 1 and 7, the second attenuating layer 230 isselectively etched through the openings 250 a of the resist layer 250 toform openings in the second attenuating layer 230 aligned with theopenings 250 a of the resist layer 250. The etchant to etch the secondattenuating layer 230 may be designed to have a higher etchingselectivity over the substrate 210 and the first attenuating layer 220.The resist layer 250 is removed thereafter, using either wet strippingor plasma ashing. In one embodiment, the patterned second attenuatinglayer 230 may have an exemplary structure as illustrated in FIG. 17 as atop view of the phase shift mask 200. The mask 200 includes thesubstrate 210, the patterned second material layer 230, and theintegrated circuit (IC) cell regions 270 having the patterned firstattenuating layer 200 formed thereon. The mask 200 may include otherfeatures such as various alignment marks (not shown). The patternedsecond attenuating layer 230 may substantially cover the frame regionsto achieve a black out. Since the patterned second attenuating layer 230has non-critical dimensions and relatively loose resolution requirementrelative to the IC features formed by the first exposure, the secondexposure in scanning mode can meet the resolution requirement and reducethe second exposure time and manufacturing cost. The method 100 can beimplemented for making an attenuating phase shift mask in one example.

Referring now to FIG. 8, a method 300 describes a lithography processaccording to another embodiment of the present disclosure. FIGS. 9through 14 provide sectional views of an exemplary phase shift mask atvarious fabrication stages fabricated using the method of FIG. 8.

The method 300 begins at step 302 by providing a mask 400 having asubstrate 410, an attenuating layer 430, and a first imaging layer 440,as illustrated in FIG. 9. The mask 400 is also referred to as a maskblank, to be patterned to form a phase shift mask for use insemiconductor fabrication (such as lithography patterning processes).The substrate 410 may be substantially similar to the substrate 210 ofFIG. 2.

The attenuating layer 430 is disposed on the substrate 410. Theattenuating layer 430 is designed as an absorption layer and is opaqueto the radiation beam used for lithography processing in semiconductormanufacturing. The attenuating layer 430 may be substantially similar tothe second attenuating layer 230 of FIG. 2 in term of material. In oneembodiment, the attenuating layer 430 has a transmission less than about30%. In another embodiment, the attenuating layer 430 includes chromium.Alternatively, the attenuating layer 430 may include a material selectedfrom the group consisting of Cr, CrN, Mo, Nb₂O₅, Ti, Ta, CrN, MoO₃, MoN,Cr₂O₃, TiN, ZrN, TiO₂, TaN, Ta₂O₅, SiO₂, NbN, Si₃N₄, ZrN, Al₂O₃N, or acombination thereof. The method of forming the attenuating layer 430 mayinclude CVD, PVD, plating, and/or other suitable processes similar tothose used to form the second attenuating layer 230 of FIG. 2.

The first imaging layer 440 is formed on the substrate 410 for the firstexposure and patterning described below. The first imaging layer 440 issubstantially similar to that of the imaging layer 240 of FIG. 2 interms of composition, configuration, and formation.

The method 300 proceeds to step 304 to perform a first exposure appliedto the first imaging layer 440. The first exposure to the imaging layer440 is substantially similar to the first exposure of the method 100 andutilizes a radiation beam such as electronic beam (e-beam) or laser beamto expose the imaging layer 440 in a writing mode. The first exposuremay utilize the e-beam writer 500 of FIG. 15. After the first exposure,other lithography processes may be applied to the imaging layer 440 toform various openings such as openings 440 a and 440 b, designedaccording to a predefined structure to be imaged onto a semiconductorwafer or other integrated circuit substrate. The attenuating layer 430is exposed within the openings 440 a and 440 b of the resist layer 440,as illustrated in FIG. 10. The other lithography processes applied tothe resist layer 440 may include post-exposure baking, developing, andhard baking.

Referring to FIGS. 8 and 11, the method 300 proceeds to step 306 byetching the attenuating layer 430 through the openings 440 a and 440 bof the patterned imaging layer 440 to form various openings 430 a and430 b through the first and second attenuating layers 420 and 430. Thetransparent substrate 410 is therefore exposed within the openings 430 aand 430 b. The etchant for etching the attenuating layer 430 may bechosen or designed to have a higher etching selectivity over thetransparent substrate 410. The etchant may include halogens species suchas fluorine, chlorine and bromine. The imaging layer 440 is removedafter the etching process. Then the substrate 410 is etched using theattenuating layer 430 as a hard mask, to form various trenches in thesubstrate 410 defining phase shift features therein. Alternatively, thesubstrate 410 may be etched using the imaging layer 440 as a mask andthe imaging layer 440 is removed thereafter. The various trenches formedin the substrate 410 may have a depth such that a radiation beamdirected toward and through one of the trenches has a phase shiftrelative to the radiation beam directed through the unetched substrate410. The radiation beam is referred to a radiation beam implemented tothe mask 400 during a semiconductor wafer fabrication. The radiationbeam may be ultraviolet and/or can be extended to include otherradiation beams such as ion beam, x-ray, extreme ultraviolet (EUV), deepultraviolet (DUV), and other proper radiation energy. In one embodiment,the trenches formed in the substrate 410 has a phase shift about 180degrees. More specifically, the trenches in the substrate 410 may have adepth about λ/[2(n−1)], wherein λ is the wavelength of the radiationbeam implemented to the mask 400 during semiconductor wafer fabrication,and n is refractive index of the transparent substrate 410 relative tothe radiation beam. In another embodiment, the trenches in the substrate410 may have a phase shift ranging between about 120 degrees and 240degrees. Specifically, the trenches in the substrate 410 may have adepth ranging between λ/[3×(n−1)] and 2λ/[3×(n−1)] to realize a phaseshift in the desired range.

Referring to FIGS. 8 and 12, the method 300 proceeds to step 308 byforming a second imaging layer (resist layer) 450 on the mask 400. Theresist layer 450 is formed on the attenuating layer 430 and also on thetransparent substrate 410 within the trenches formed in the substrate410. The exemplary resist material for the second imaging layer 450 issensitive to the radiation beam of the second exposure described below.In one example, the second imaging layer includes chemical amplificationresist. The resist layer 450 may be formed by a spin-on coating processand may be soft baked thereafter.

Referring to FIGS. 8 and 13, the method 300 proceeds to step 310 byperforming a second exposure to the second imaging layer 450 utilizing aradiation energy in scanning mode. The second exposure utilizes a lightenergy such as UV light as the radiation energy and another mask havinga predefined pattern for the second exposure. The second exposureapplied to the resist layer 450 utilizes a lithography exposure toolsuch as a stepper or a scanner to scan a predefined pattern on areticle, as illustrated in FIG. 16, in a way substantially similar tothat of the second exposure of the method 100. After the secondexposure, other lithography processes may be applied to the resist layer450 to form various openings such as an openings 450 a, designedaccording to a predefined structure to be imaged onto a semiconductorwafer or other integrated circuit substrate. The attenuating layer 430and the transparent substrate 410 are exposed within the openings 450 aof the resist layer 450. The other lithography processes applied to theresist layer 450 may include post-exposure baking, developing, and hardbaking.

Referring to FIGS. 8 and 14, the attenuating layer 430 is selectivelyetched through the openings 450 a of the resist layer 450 to formopenings therein aligned with the openings 450 a of the resist layer450. The etchant to etch the attenuating layer 430 may be designed tohave a higher etching selectivity over the substrate 410. The resistlayer 450 is removed thereafter, using either wet stripping or plasmaashing. In one embodiment, the patterned attenuating layer 430 may havean exemplary structure as the attenuating layer 430 of FIG. 17 in a topview but the integrated circuit (IC) cell regions 470 includes variouschromeless phase shift features formed in the substrate 410 by theprevious steps. Since the patterned attenuating layer 430 hasnon-critical dimensions and relatively loose resolution requirementrelative to the IC features formed in the substrate, the lithographyexposure in scanning mode can meet the resolution requirement and reducethe second exposure time and manufacturing cost. The method 300 can beimplemented to mask a chromeless phase shift mask as detailed above.

The processes making a phase shift mask, are described in embodimentsfor making various phase shift masks including attenuating phase shiftmask and chromeless phase shift mask. Other masks may be formed by thedisclosed method utilizing the first exposure in writing mode withe-beam or laser beam to pattern critical features in a first layer andutilizing the second exposure in scanning mode with UV and a mask topattern non-critical features in a second layer. The disclosed methodmay have variations without departure from the spirit and the scope ofthe present disclosure. For example, the phase shift mask 200 may beextended to include more then two attenuating layers to realize multiplephase-shift assistant features. In further embodiment, each attenuatinglayer may include more than one film for optimized manufacturing andperformance. The masks 200 and/or 400 may not only be used to fabricatea semiconductor wafer, but may be alternatively used to pattern othersubstrates such as a glass substrate used to form a thin film transistorliquid crystal display (TFT-LCD) substrate. The phase shift structuresformed in the IC region such as attenuating phase shift mask 200 andchromeless phase shift mask 400 may include not only IC features butalso various optical proximity correction (OPC) features to enhance thelithography patterning resolution when using the above phase shift masksfor IC fabrication. For example, assistant features such as scatteringbars may be added and formed on the mask with IC features in phaseshift. The above methods for fabricating a phase shift mask may beimplemented in different sequence. In one embodiment for making the mask200, the second attenuating layer is patterned utilizing an exposure inscanning mode and then the first attenuating layer is patternedthereafter utilizing another exposure in writing mode. In anotherembodiment for making the mask 400, the attenuating layer is patternedutilizing an exposure in scanning mode and then the transparentsubstrate is patterned thereafter utilizing another exposure in writingmode. In another embodiment for making the mask 200, after the firstexposure applied to the first imaging layer, the second attenuatinglayer is etched. Then the imaging layer is removed. Thereafter the firstattenuating layer is etched using the second attenuating layer as a hardmask. To implement the first exposure and second exposure describedabove, the e-beam system 500 and the exposure system 600 may beintegrated for both mechanisms and functions such that the first andsecond exposures can be all implemented therein for mask manufacturingefficiency and quality. In another embodiment, the e-beam system 500 maybe alternatively replaced by a laser writer.

Thus the present disclosure provides a method of making a mask. Themethod includes providing a substrate having a first attenuating layeron the substrate and a first imaging layer on the first attenuatinglayer; performing a first exposure to the first imaging layer using afirst radiation energy in writing mode; performing a first etching tothe first attenuating layer; performing a second etching to thesubstrate; forming a second imaging layer on the first attenuating layerand the substrate; performing a second exposure to the second imaginglayer using a light energy and another mask; and performing a thirdetching to the first attenuating layer after the second exposure.

As one example of the method, the substrate may include a transparentsubstrate and a second attenuating layer disposed on the transparentsubstrate. The second etching includes etching the second attenuatinglayer to form phase shift features. The first attenuating layer includesMoSi and the second attenuating layer include chrome. In another exampleof the method, the substrate includes a transparent material layer andthe first attenuating layer includes chrome adjacent to the transparentmaterial layer. The second etching includes etching the transparentmaterial layer to form phase shift features. In one example, the firstradiation energy includes an electronic beam (e-beam). In anotherexample, the first radiation energy includes an ultra-violet (UV) beamfrom a light source.

The present disclosure also provides another embodiment of a method formasking phase shift mask. The method includes providing a mask blankhaving a transparent substrate; a first attenuating layer on thetransparent substrate; a second attenuating layer on the firstattenuating layer; and a first imaging layer on the second attenuatinglayer. The method also includes performing a first exposure to the firstimaging layer using a first radiation energy in writing mode; thereafterperforming a first etching to the first attenuating layer and the secondattenuating layer; forming a second imaging layer on the firstattenuating layer and the transparent substrate; performing a secondexposure to the second imaging layer using a second radiation energy inscanning mode; and thereafter performing a second etching to the firstattenuating layer.

In this method, the first radiation energy may include an e-beam. Thesecond radiation energy may include ultraviolet light. The secondexposure may include utilizing another mask. The method may furtherinclude removing the first imaging layer after the first etching. Themethod may further include removing the second imaging layer after thesecond etching. In this method, the first attenuating layer may includeMoSi. The second attenuating layer may include Cr. Alternatively, thefirst attenuating layer may include a material selected from the groupconsisting of MoSi, ToSi₂, iron oxide, inorganic material, Mo, Nb₂O₅,Ti, Ta, CrN, MoO₃, MoN, Cr₂O₃, TiN, ZrN, TiO₂, TaN, Ta₂O₅, SiO₂, NbN,Si₃N₄, ZrN, Al₂O₃N, and combinations thereof. The second attenuatinglayer may include a material selected from the group consisting of Cr,CrN, Mo, Nb₂O₅, Ti, Ta, CrN, MoO₃, MoN, Cr₂O₃, TiN, ZrN, TiO₂, TaN,Ta₂O₅, SiO₂, NbN, Si₃N₄, ZrN, Al₂O₃N, and combinations thereof.

The present disclosure also provides another embodiment of a method formaking a phase shift mask. The method includes providing a substratehaving a phase shift layer on the substrate, and an attenuating layer onthe phase shift layer; performing a first exposure of the phase shiftlayer and the attenuating layer using an electronic beam (e-beam);performing a first etching to the phase shift layer and the attenuatinglayer to define a device pattern; performing a second exposure of theattenuating layer using a light source and a mask; and performing asecond etching to the attenuating layer. In this method, the attenuatinglayer may include Cr. The phase shift layer may include MoSi.

Although embodiments of the present disclosure have been described indetail, those skilled in the art should understand that they may makevarious changes, substitutions and alterations herein without departingfrom the spirit and scope of the present disclosure. Accordingly, allsuch changes, substitutions and alterations are intended to be includedwithin the scope of the present disclosure as defined in the followingclaims. In the claims, means-plus-function clauses are intended to coverthe structures described herein as performing the recited function andnot only structural equivalents, but also equivalent structures.

1. A method comprising: forming a first attenuating layer over asubstrate and a first imaging layer over the first attenuating layer;patterning the first imaging layer; performing a first etching topattern the first attenuating layer using the patterned first imaginglayer as a mask; performing a second etching to the substrate; forming asecond imaging layer over the patterned first attenuating layer and theetched substrate; patterning the second imaging layer; and after thepatterning the second imaging layer, performing a third etching to thepatterned first attenuating layer, wherein the patterned firstattenuating layer is patterned via the third etching such that a portionof the patterned first attenuating layer substantially covers a frameregion to achieve a black out.
 2. The method of claim 1, wherein thepatterning of the first imaging layer includes performing a firstexposure process and a first development process, and wherein thepatterning of the second imaging layer includes performing a secondexposure process and a second development process.
 3. The method ofclaim 2, wherein the performing of the first exposure process includesusing a radiation energy in writing mode to expose the first imaginglayer.
 4. The method of claim 3, wherein the radiation energy comprisesat least one of an electron beam (e-beam) and a laser beam.
 5. Themethod of claim 2, wherein the performing of the second exposure processincludes using a radiation energy to expose the second imaging layer. 6.The method of claim 5, wherein the radiation energy comprises at leastone of an ion beam, an x-ray beam, an ultra-violet beam, an extremeultra-violet beam, and a deep ultra-violet beam.
 7. The method of claim1, wherein the forming of the first attenuating layer over the substrateand the first imaging layer over the first attenuating layer includesforming a second attenuating layer over the substrate.
 8. The method ofclaim 7, wherein the performing of the second etching to the substrateincludes etching the second attenuating layer.
 9. A method comprising:forming a first attenuating layer over a substrate, a second attenuatinglayer over the first attenuating layer, and a first imaging layer overthe second attenuating layer; patterning the first imaging layer; afterthe patterning of the first imaging layer, patterning the firstattenuating layer and the second attenuating layer using the patternedfirst imaging layer as a mask; forming a second imaging layer on thepatterned second attenuating layer and the substrate; patterning thesecond imaging layer; and after the patterning of the second imaginglayer, etching the patterned second attenuating layer, wherein thesecond attenuating layer is patterned a second time such that the secondattenuating layer substantially covers a frame region to achieve a blackout.
 10. The method of claim 9, wherein the patterning of the firstimaging layer includes performing a first exposure process and a firstdevelopment process to expose portions of the second attenuating layer,and wherein the patterning of the second imaging layer includesperforming a second exposure process and a second development process toexpose portions of the patterned second attenuating layer.
 11. Themethod of claim 10, wherein the performing of the first exposure processincludes using a first radiation energy in writing mode expose the firstimaging layer, and wherein the performing of the second exposure processincludes using a second radiation energy to expose the second imaginglayer.
 12. The method of claim 9, further comprising removing thepatterned first imaging prior to the forming of the second imaging layeron the patterned second attenuating layer and the substrate.
 13. Themethod of claim 9, wherein the patterning of the first attenuating layerand the second attenuating layer using the patterned first imaging layeras the mask includes etching the first attenuating layer and the secondattenuating layer using the patterned first imaging layer to expose aportion of the substrate.
 14. The method of claim 9, wherein the firstattenuating layer includes MoSi and the second attenuating layerincludes chromium.
 15. The method of claim 9, wherein the substrate is atransparent substrate, wherein the first attenuating layer comprises amaterial selected from the group consisting of MoSi, iron oxide,inorganic material, Mo, Nb₂O₅, Ti, Ta, CrN, MoO₃, MoN, Cr₂O₃, TiN, ZrN,TiO₂, TaN, Ta₂O₅, SiO₂, NbN, Si₃N₄, ZrN, Al₂O₃N, and combinationsthereof, and wherein the second attenuating layer comprises a materialselected from the group consisting of Cr, CrN, Mo, Nb₂O₅, Ti, Ta, CrN,MoO₃, MoN, Cr₂O₃, TiN, ZrN, TiO₂, TaN, Ta₂O₅, SiO₂, NbN, Si₃N₄, ZrN,Al₂O₃N, and combinations thereof.
 16. A method comprising: providing asubstrate having a first attenuating layer over the substrate and afirst imaging layer over the first attenuating layer; patterning thefirst imaging layer, wherein the patterning of the first imaging layerincludes performing a first exposure to the first imaging layer andperforming a first development process; performing a first etching topattern the first attenuating layer to expose a portion of thesubstrate; forming a second imaging layer over the first attenuatinglayer and the exposed portion of the substrate; patterning the secondimaging layer to expose a portion of the patterned first attenuatinglayer, wherein the patterning of the second imaging layer includesperforming a second exposure to the second imaging layer and performinga second development process; and after the patterning of the secondimaging layer, performing a second etching to the exposed portion of thepatterned first attenuating layer, wherein the exposed portion of thepatterned first attenuating layer is patterned via the second etchingsuch that a portion of the patterned first attenuating layersubstantially covers a frame region to achieve a black out.
 17. Themethod of claim 16, further comprising performing a second etching tothe exposed portion of the substrate to define phase shift features inthe substrate.
 18. The method of claim 16, wherein the providing of thesubstrate having the first attenuating layer over the substrate and thefirst imaging layer over the first attenuating layer includes providingthe substrate having a second attenuating layer over the substrate. 19.The method of claim 18, wherein the performing of the first etching topattern the first attenuating layer to expose the portion of thesubstrate includes etching the second attenuating layer.
 20. The methodof claim 18, wherein the first attenuating layer includes chromium andthe second attenuating layer includes MoSi.